Composite panel edge treatments and joints and cargo body having same

ABSTRACT

A cargo body includes sidewalls constructed of pairs of panels secured together at respective joints. Each of the plurality of panels is a composite panel having a core, an interior skin secured to a first side of the core facing the cargo receiving volume, and an exterior skin secured to a second opposite side. Each joint includes an interior splice plate and an exterior splice plate, and co-facing edge portions of the adjacent pair of panels are sandwiched between the interior and exterior splice places. Each edge portion defines a region of reduced core thickness in which a core thickness measured between the respective interior and exterior skins is less than a maximum core thickness. A recess is formed by the pair of interior or exterior skins to receive the corresponding splice plate, such that the corresponding one of the interior and exterior splice plate is nested into the recess.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/730,729, filed Jun. 4, 2015, which claims priority to U.S.Provisional Patent Application 62/007,807, filed Jun. 4, 2014, theentire contents of both of which are incorporated by reference herein.

BACKGROUND

The invention relates to cargo body construction, for example, forover-the-road trailers pulled by semi tractors. In particular, theinvention relates to trailer sidewall panels and joints for suchsidewall panels, in addition to trailer walls, floors, and roofs.

In so-called “sheet and post” construction, thin sheets are joined withstructural posts such that the thin sheets define a majority of thesurface area that encloses the cargo volume while the posts are reliedupon for the required strength and rigidity of the wall. In suchconstruction, joint locations typically each present a locally increasedwall thickness where the post protrudes to a significant extent beyondthe sheets. So-called “plate wall” construction alleviates this drawbackto at least some degree by utilizing substantially thicker, load bearingwall panels with splice plates to secure the edges of adjacent panels.Although modern plate wall construction has extended to the use ofcomposite panels including sheet metal skins and low density fillermaterials, there remains a need in the field for further advancement inthe joint structures between wall panels for constructing cargo bodiesthat are lightweight, efficient to manufacture and assemble, and costeffective.

SUMMARY

In some embodiments, the invention provides a cargo body including afloor, a roof and a plurality of sidewalls extending between the floorand the roof to define a cargo receiving volume in cooperation with thefloor and the roof, wherein each one of the plurality of sidewalls isconstructed of a plurality of panels including adjacent pairs of panelssecured together at respective joints, and wherein each of the pluralityof panels is an assembled panel having a core, an interior skin securedto a first side of the core facing the cargo receiving volume, and anexterior skin secured to a second side of the core opposite the firstside. Each of the joints is formed to include overlapping edge portionsof a first one of the adjacent pair of panels and a second one of theadjacent pair of panels. Each of the overlapping edge portions has athickness less than 20 percent of a total panel thickness of thecorresponding one of the adjacent pair of panels such that the jointformed thereby defines a recess between co-facing edge portions of thefirst and second ones of the adjacent pair of panels. A profile insertdefining a longitudinal channel is positioned in the recess defined bythe overlapping edge portions at each joint. Each joint is secured byfixedly attaching the profile insert to the overlapping edge portions.

In some embodiments, the invention provides a cargo body including afloor, a roof and a plurality of sidewalls extending between the floorand the roof to define a cargo receiving volume in cooperation with thefloor and the roof, wherein each one of the plurality of sidewalls isconstructed of a plurality of panels including adjacent pairs of panelssecured together at respective joints, and wherein each of the pluralityof panels is an assembled panel having a core, an interior skin securedto a first side of the core facing the cargo receiving volume, and anexterior skin secured to a second side of the core opposite the firstside. Each of the joints is formed as a lap joint in which an edgeportion of a first one of the adjacent pair of panels overlaps a portionof a second one of the adjacent pair of panels, and an edge portion ofthe second one of the adjacent pair of panels overlaps a portion of thefirst one of the adjacent pair of panels. The first one of the adjacentpair of panels has a reduced-thickness core portion throughout the edgeportion in which a core thickness measured between the interior andexterior skins is less than half of a maximum core thickness of thefirst one of the adjacent pair of panels. The second one of the adjacentpair of panels has a reduced-thickness core portion throughout the edgeportion in which a core thickness measured between the interior andexterior skins is less than a maximum core thickness of the second oneof the adjacent pair of panels.

Some embodiments of the present invention provide a cargo body includinga floor, a roof, and a plurality of sidewalls extending between thefloor and the roof to define a cargo receiving volume in cooperationwith the floor and the roof, wherein each one of the plurality ofsidewalls is constructed of a plurality of panels including adjacentpairs of panels secured together at respective joints, and wherein eachof the plurality of panels is a composite panel having a core, aninterior skin secured to a first side of the core facing the cargoreceiving volume, and an exterior skin secured to a second side of thecore opposite the first side. Each of the joints includes an interiorsplice plate and an exterior splice plate, and co-facing edge portionsof the adjacent pair of panels are sandwiched between the interior andexterior splice places. Each edge portion defines a region of reducedcore thickness in which a core thickness measured between the respectiveinterior and exterior skins is less than a maximum core thicknessmeasured between the respective interior and exterior skins. A recess isformed by the pair of interior skins or by the pair of exterior skins toreceive the corresponding one of the interior and exterior spliceplates, such that the corresponding one of the interior and exteriorsplice plate is nested into the recess.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a trailer, including a plurality ofsidewalls having sidewall joints, according to one embodiment of thepresent invention.

FIG. 2 is an alternate perspective view of the trailer of FIG. 1.

FIG. 3 is a cross-sectional view of one of the sidewall joints of thetrailer shown in FIGS. 1 and 2, taken along line 3-3 of FIG. 1.

FIG. 4 is a cross-sectional view of a sidewall joint of the trailershown in FIGS. 1 and 2, according to a second embodiment.

FIG. 5 is a cross-sectional view of a sidewall joint of the trailershown in FIGS. 1 and 2, according to a third embodiment.

FIG. 6 is a cross-sectional view of a sidewall joint of the trailershown in FIGS. 1 and 2, according to a fourth embodiment.

FIG. 7 is a cross-sectional view of a sidewall joint of the trailershown in FIGS. 1 and 2, according to a fifth embodiment.

FIG. 8 is a cross-sectional view of a sidewall joint of the trailershown in FIGS. 1 and 2, according to a sixth embodiment. The joint formsa recess to accommodate an integral profiled component.

FIG. 9 is a cross-sectional view of a sidewall joint of the trailershown in FIGS. 1 and 2, according to a seventh embodiment. The jointforms a recess to accommodate an integral profiled component.

FIG. 10 is a cross-sectional view of a single sidewall panel including arecess formed to receive a profiled component that does not extend alongan edge portion to form a joint.

FIG. 11 is a cross-sectional view of a composite roof panel and an upperrail of the trailer of FIG. 1, and a joint therebetween.

FIG. 12 is a detail view of a portion of the roof joint of FIG. 11.

FIG. 13 is a cross-sectional view of a composite floor platen of a floorof the trailer of FIGS. 1 and 2.

FIG. 14 is a first perspective view of one exemplary profiled core sheetfor use in panels throughout the trailer of FIGS. 1 and 2.

FIG. 15 is a second perspective view of the profiled core sheet of FIG.14.

FIG. 16 is a cross-sectional view of a trailer sidewall joint accordingto yet another embodiment. The joint forms a recess with tapered sidesto accommodate an integral profiled component.

FIG. 17 is an end view of one of the sidewall panels of FIG. 16.

FIG. 18 is a detail view of FIG. 17, illustrating the mid-panel recessin further detail.

FIG. 19 is a detail view of FIG. 17, illustrating one of the distaledges of the panel in further detail.

FIG. 20 illustrates a trailer sidewall for a wedge-type construction,utilizing the joint construction of FIGS. 16-19.

DETAILED DESCRIPTION

FIGS. 1 and 2 illustrate a cargo body configured as a trailer 10 forover-the-road use with a truck to transport large cargo volumes. Asshown, the trailer 10 is a semi-trailer configured for use with a roadtractor (i.e., in forming a so-called 18-wheeler). Aspects of theinvention are not necessarily limited to such a trailer, and othertrailer and cargo body configurations are understood as optional. Thetrailer 10 includes a chassis having axles with multiple sets of wheels,although similar cargo bodies may be provided with alternate rollingchassis constructions or none at all. The trailer 10 defines a length Lin a longitudinal or transport direction. The length L can be 53 feet insome constructions, although the trailer can be manufactured to otherlengths greater than or less than 53 feet. Perpendicular to thelongitudinal direction, the trailer 10 defines a width W and a height H.The width W cooperates with the length L to define a plan view footprintof the trailer 10, while the height H is measured perpendicular to thefootprint (i.e., perpendicular to the ground). Subtracting for wallthicknesses, the length L, the width W, and the height H cooperate todefine a cargo receiving interior volume of the trailer 10. The trailer10 includes a plurality of sidewalls 12, including two primarylengthwise sidewalls 12 and a sidewall 12 facing the leading directionand spanning between the two primary lengthwise sidewalls 12. All of thesidewalls 12 extend between a roof 13 of the trailer 10 and a floor 14of the trailer 10. As discussed in further detail below, the sidewalls12 can be constructed of pairs of panels 15, 16 joined together byjoints extending parallel to the direction of the trailer height Hbetween the roof 13 and the floor 14. Top rails 22 and bottom rails 24are provided to flank and secure the upper and lower edges of each ofthe sidewall panels 15, 16. At the rear of the trailer 10 as shown inFIG. 2, at least one door panel 18 is provided to selectively open foraccessing the interior cargo volume for loading and unloading.

A first panel edge treatment and a configuration for joining adjacentsidewall panels 15, 16 are shown in FIG. 3. Although a single joint isshown, it is understood that this structure may be repeated throughoutthe trailer 10 at each location where two sidewall panels are joined. Inthe illustrated construction, the sidewall panels 15, 16 are positionedlaterally side-by-side such that the joint therebetween extends in thedirection of the trailer height H, but other orientations may beprovided in alternate constructions. The joint of FIG. 3 consists of ashiplap joint in which a multi-layer flange or edge portion 15A of thefirst panel 15 overlaps a main portion of the second panel 16, and amulti-layer flange or edge portion 16A of the second panel 16 overlaps amain portion of the first panel 15. This results in the construction ofa Z-shaped joint interface as shown in FIG. 3, including two 90-degreecorners.

Each of the panels 15, 16 can have a composite construction including acore sheet, or simply, core 30, and respective interior and exteriorskins 32, 34. The interior skin 32 is secured to a first side of thecore 30 facing the cargo receiving volume of the trailer 10, and theexterior skin 34 is secured to a second side of the core 30 opposite thefirst side and facing the exterior of the trailer 10. Each of theinterior and exterior skins 32, 34 can have a thickness T perpendicularto sheet plane that is not less than 0.008 inch and not more than 0.080inch in some constructions, and more particularly not more than 0.050inch (e.g., 0.016 inch). The interior and exterior skins 32, 34 can begalvanized steel sheets, or aluminum, among other materials.

The core 30 of each of the panels 15, 16 can define a thickness T1(e.g., maximum thickness) that is present throughout the main portion ofthe panel 15, 16, but not in the respective edge portions 15A, 16A. Insome constructions, the core thickness T1 can be 0.100 inch or greater,more particularly 0.250 inch or greater, up to 1.5 inches, or more. Forexample, the core thickness T1 can be 0.500 inch. Although the core 30of each panel 15, 16 extends into the respective edge portions 15A, 16A,each core 30 defines a reduced-thickness portion 30A, throughout theregions defined by the edge portions 15A, 16A, the portion 30A having athickness T2 significantly less than the maximum core thickness T1(e.g., reduced core thickness T2 is less than half of maximum corethickness T1). The thickness T2 of the core portion 30A is not less than0.008 inch and not more than 0.016 inch, in some constructions, and moreparticularly, may be about 0.011 inch (0.010 inch to 0.012 inch) in someconstructions. A total thickness T3 of each of the edge portions 15A,16A can be 0.100 inch or less, or further 0.060 inch or less. In someconstructions, the thickness T3 of each of the edge portions 15A, 16A isless than 0.050 inch (e.g., 0.043 inch steel or 0.176 inch aluminum).The core thicknesses T1, T2 are measured between the interior andexterior skins 32, 34, perpendicular to the principal parallel planardirections of the interior and exterior skins 32, 34. The thicknesses T3of the edge portions 15A, 16A are taken in this direction as well.

The cores 30 of the panels 15, 16 can be profiled sheets of metal (e.g.,carbon steel, mild steel, stainless steel, galvanized steel, or othermaterials such as aluminum). Each core 30 can be constructed byprofiling (e.g., embossing) a flat starting sheet such that the finalcore thickness T1 is thicker than the material thickness of the startingsheet. For example, each core 30 can be constructed by profiling a flatstarting sheet such that the final core thickness T1 is more than 10times the material thickness of the starting sheet, and in some cases ismore than 20 times, and even more than 50 times the material thicknessof the starting sheet. The thickness T2 of the core portion 30A in theedge portions 15A, 16A may be equivalent to the starting sheetthickness. Each core 30 can be a metal sheet of undulating form (e.g.,repeating waves of any type and shape in both length and widthdirections of the sheet, such as an anticlastic form) having an array ofinterspersed peaks and valleys, such as uniformly-interspersed peaks andvalleys. In some embodiments, the cores 30 can be formed by dualembossing, which is to say embossed in two directions from the planedefined by the starting sheet. The cores 30 may be an adapted form ofstructures described in U.S. Patent Application Publication No.2013/0244006, U.S. Patent Application Publication No. 2007/0243408, U.S.Patent Application Publication No. 2007/0114269, U.S. Patent ApplicationPublication No. 2009/0123709, U.S. Pat. No. 8,835,016, or U.S. Pat. No.7,757,931, assigned to Celltech Metals, Inc., the entire contents of allof which are incorporated by reference herein. However, it should benoted that certain aspects of the invention are not limited to the exactcore constructions disclosed in the incorporated documents, or eventheir general type. For example, the cores 30 of one or more panels 15,16 can be constructed of non-metallic materials such as wood, plastic(e.g., extruded polyethylene (PE), PE-based foam, blow molded,thermoset, etc.), composite materials, paper, foam, ceramic, and thelike. Some such materials may be formed in a shape similar to theillustrated cores 30, or in alternate forms, including flat orplate-like, honeycomb structure, and others. Regardless of the coreconstruction, other features of the panels and joints may conform to theillustrations and description herein.

Returning now to the interface between the two panels 15, 16 at thejoint of FIG. 3, each of the edge portions 15A, 16A is made up ofmultiple layers—in the illustrated construction, three layers. Withrespect to the edge portion 15A of the first panel 15, the layersinclude the continuation of the interior skin 32, which extends in planewith the portion of the interior skin 32 covering the majority of thepanel 15, a portion of the exterior skin 34, which is separated from themajority portion of the exterior skin 34 by two 90-degree bends to lieadjacent the interior side of the interior skin 32 of the second panel16, and the core portion 30A positioned therebetween. As shown, the coreportion 30A is flat (i.e., planar, or unprofiled). The edge portion 16Aof the second panel 16 has substantially the same construction as thatof the edge portion 15A of the first panel 15, except that theconfiguration of the interior and exterior skins 32, 34 is reversed.That is, the exterior skin 34 extends beyond the full-thickness portionof the core 30, onto the full-thickness portion of the core of the firstpanel 15, and the interior skin 32 is formed with two 90-degree bendssuch that a portion of the interior skin 32 of the second panel 16 liesadjacent the exterior skin 34 of the first panel 15. Although the jointis shown to include multiple 90-degree bends, each of the panels 15, 16may include corners of greater than 90 degrees for assembly purposes,and can be formed by bending the corresponding ones of the skins 32, 34less than 90 degrees to form an interior angle greater than 90 degrees(see interior skin 1032 of FIG. 16). The joining of the first and secondpanels 15, 16 can be via one, two, or more rows of mechanical fasteners38 (e.g., screws, rivets, etc.), welding, adhesive bonding, or acombination of methods. An exemplary arrangement for joining by a singlerow of rivets 38 is shown in phantom lines in FIG. 3. The rivets 38 mayalso be installed from the opposite side, in mirrored orientation fromthat shown.

FIG. 3 also shows each edge portion 15A, 16A laid upon the surface ofthe adjoining panel 15, 16. A configuration that allows for part or allof the thickness T3 of the edge portions 15A, 16A to be recessed intothe surface of the adjoining panel 15, 16 is also contemplated. If fullyrecessed, an entirely smooth transition is provided along the innerand/or outer surfaces of the two mating panels 15, 16 with the edgeportions 15A, 16A made flush with the respective inner and outersurfaces of the interior and exterior 32, 34 skins of the adjoiningpanel 15, 16. Even in the construction shown, where the full thicknessT3 of each edge portion 15A, 16A is raised beyond the respective innerand outer surfaces of the interior and exterior 32, 34 skins of theadjoining panel 15, 16, the transition or “lip” at this interface mayprovide a smooth joint transition, unlikely to impede or snag cargo onthe interior and providing a smooth exterior trailer surface. Forexample, conventional joint constructions will introduce protrudingjoint hardware that extends perpendicular from the panel surface by adistance of ⅝ inch to 1.0 inch, whereas the edge portion thickness T3 asdisclosed herein may be 0.100 inch or less, characterized herein assmooth. Alternatively, the edge can be offset in order to create aplanar surface across the joint, i.e., faces of the skins 32, 34 of eachpanel 15, 16 planar to the other adjacent panel 15, 16.

A panel edge treatment and a corresponding joint construction accordingto a second embodiment are shown in FIG. 4. A shiplap joint is formed,similar to that shown and described above in reference to FIG. 3, exceptas noted below. Therefore, the above description is relied upon fordisclosing all features not repeated directly in reference to FIG. 4 toavoid redundancy. Each panel 115, 116 is formed to include a flange oredge portion 115A, 116A extending from a main portion of the panel 115,116. As with the joint of FIG. 3, the core 30 of each panel 115, 116defines a maximum thickness T1 throughout the main portion, but notwithin the edge portions 115A, 116A, which instead includereduced-thickness core portions 30A having thickness T2. Rather than aflat core portion as in FIG. 3, the reduced-thickness core portions 30Aof FIG. 4 can be profiled in any manner, including in a manner similarto the main portions of the core 30, but to a lesser extent to define asmaller overall thickness. The reduced-thickness core portions 30A ofFIG. 4 can also be formed to include a higher profile array density(i.e., a higher number of individual profile shapes per unit area). Asshown, each panel edge portion 115A, 116A can be approximately half(e.g., 40 to 60 percent) the thickness of the overall panel (T1+2T), andthe thickness T2 of each core portion 30A can be approximately half themaximum core thickness T1. The individual thicknesses of the two coreportions 30A do not need to be equal, although the sum should be equalto the overall thickness T1, or just less to account for theinterstitial skins. The result of this particular flange structure isthat the edge portions 115A, 116A only overlap with each other andneither one extends to overlap with the main portion of the adjoiningpanel 115, 116. It also results in the edge portions 115A, 116A beingformed with a high percentage of void space, whereas the edge portions15A, 16A of FIG. 3 are illustrated as being formed of solid materialthroughout.

The interior and exterior skins 32, 34 are bent to enclose the co-facingedges of each panel 115, 116. In addition to the Z-shaped bend profiles(i.e., double 90-degree bends, or bends forming interior angles greaterthan 90 degrees) of the exterior skin 34 of the first panel 115 and theinterior skin 32 of the second panel 116, an additional bend is providedin each of the interior skin 32 of the first panel 115 and the exteriorskin 34 of the second panel 116. The joining of the panels 115, 116 canbe via one or more rows of mechanical fasteners (e.g., screws, rivets),welding, adhesive bonding, or a combination of methods. An alternativeto the illustrated single row of rivets 38 is to allow one or both ofthe skins 32, 34 to continue and overlap the adjoining panel either onits surface as shown in FIG. 3 or by recess configuration as mentionedabove. This additional overlap can provide another area for receivingone or more additional rows of mechanical fasteners, or other fasteningmeans. In such cases, the core 30 can be provided with a further-reducedthickness as compared to the thickness T2 of the core portions 30A. Forexample, the core 30 may include a flat edge portion extending withinthe additional flange. It should also be noted that the rivets 38 may beinstalled from the opposite side, in mirrored orientation from thatshown.

A panel edge treatment and a corresponding joint construction accordingto a third embodiment are shown in FIG. 5. Although not a shiplap joint,many individual features of the panels 215, 216 are generally similar tothat shown and described above in reference to FIGS. 3 and 4, and theabove description is relied upon for disclosing the details of suchfeatures. The description below focuses on the details of FIG. 5 thatdiffer from the above-described embodiments. In the construction of FIG.5, the two panels 215, 216 have co-facing edges that are abutting ornearly abutted, but the panels 215, 216 themselves do not overlap oneanother. Rather, splice plates 50 are provided to join the first andsecond panels 215, 216. Each splice plate 50 can be adhesively bondedwith both panels 215, 216 within corresponding edge portions 215A, 216Aas shown. The joining of the juncture between each splice plate 50 andthe corresponding panels 215, 216 can alternately be via a row ofmechanical fasteners (e.g., screws, rivets, etc.), welding, or acombination of methods. FIG. 5 shows the interior and exterior spliceplates 50 recessed to a flush condition with the interior surfaces ofthe interior skins 32 and the exterior surfaces of the exterior skins34, respectively. This is accomplished by providing each panel 215, 216with a corresponding edge portion 215A, 216A of reduced thickness. Asillustrated, this is achieved by providing a reduced-thickness coreportion 30A, which is reduced by a thickness equal to or approximatelyequal to a thickness T4 of the splicer plate 50 on both sides of thecore 30. As such, the reduced-thickness core portions 30A within theedge portions 215A, 216A are reduced by an amount that offsets thepresence of the splicer plates 50. However, contrary to theabove-described embodiments, the reduced-thickness core portions 30A canhave a thickness T2 that is greater than half the maximum core thicknessT1, and may be more than 80 percent of the maximum core thickness T1.Likewise, the total thickness T3 of each edge portion 215A, 216A can begreater than half the maximum panel thickness (T1+2T) throughout themain portion of the panel 215, 216, and may be more than 80 percentthereof. Although not illustrated, the option to separate the respectivepanel cores 30 and close off the co-facing edge conditions of each panel215, 216 by forming a single 90 degree bend of one or both skins 32, 34of the panels 215, 216 is also contemplated.

A panel edge treatment and a corresponding joint construction accordingto a fourth embodiment are shown in FIG. 6. Many individual features ofthe panels 315, 316 are generally similar to that shown and describedabove in reference to the above-described constructions, particularlythat of FIG. 5, and the above description is relied upon for disclosingthe details of such features. The description below focuses on thedetails of FIG. 6 that differ from the above-described embodiments. Inthe construction of FIG. 6, exterior and interior splice plates 50, 52are used to join the panels 315, 316 at their respective edge portions315A, 316A by adhesive bonding between the splice plates 50, 52 and thepanels 315A, 316A. However, the two splice plates 50, 52 may havediffering material thicknesses T4, T5 as opposed to equal materialthicknesses as shown in FIG. 5. As shown, the thickness T5 of theinterior splice plate 52 is greater than the thickness T4 of theexterior splice plate 50 (e.g., T4 is ½ to ¾ of T5), although this maybe reversed in alternate constructions. In both FIG. 5 and FIG. 6, thetwo splice plates 50, 52 can be constructed of the same or differenttype of raw material. Also, the interior splice plate 52 is thicker thanthe interior and exterior splice plates 50 of FIG. 5, and FIG. 6illustrates a deeper recess in the edge portions 315A, 316A of thepanels 315, 316 as defined by the exterior skins 34. No recess isprovided within the edge portions 315A, 316A on the exterior side, andthe exterior skins 34 of both panels 315, 316 are flat to their distaledges such that the exterior splice plate 50 sits raised from theexterior skins 34. However, the thickness T4 of the exterior spliceplate 50 may be 0.375 inch or less to maintain a smooth interior surfaceof the trailer 10. In some constructions the thickness T4 of theexterior splice plate 50 may be between 0.050 inch and 0.080 inch.Because the edge portions 315A, 316A are only recessed on one side, butrecessed to a greater extent than either recess of the construction ofFIG. 5, the thickness T2 of the reduced-thickness core portions 30A, andthe overall edge portion thickness T3 can be similar to those of FIG. 5.

The joint of FIG. 6 is constructed with a space provided between theco-facing distal edges of the adjacent panels 315, 316. This may provideadditional functionality to the joint. At least one of the splice plates(interior splice plate 52 as shown) is provided with an aperture 54 toallow engagement of a fitting for tie-off or other restraint provision(such as for stacking or blocking of the structure). The aperture 54 isprovided in communication with an interior of the joint and incommunication with the gap between the distal edges of the two panels315, 316. Closing off the edge condition of one or both panels 315, 316(e.g., by forming a single 90-degree bend of either or both skins 32,34) is again optional. Also, the fastening of the joint can be via twoor more rows of mechanical fasteners (e.g., screws, rivets, etc.),welding, adhesive bonding, or a combination of methods.

A panel edge treatment and a corresponding joint construction accordingto a fifth embodiment are shown in FIG. 7, and is similar to FIG. 6,except that the edge portions 415A, 416A are further recessed on theinterior side such that the interior splice plate 50 is recessed flushwith the interior surfaces of the interior skins 32. As such, the coreportions 30A within the edge portions 415A, 416A are reduced to athickness T2 below that of FIG. 6, and the overall edge portionthicknesses T3 are likewise reduced with respect to FIG. 6.

A panel edge treatment and a corresponding joint construction accordingto a sixth embodiment are shown in FIG. 8. The edge condition shown inFIG. 8 allows for an inclusion of a profile insert 70 inserted into theassembly of the joint. The profile insert 70 can be a track of a cargocontrol or shoring system, or auxiliary decking system. For example, theprofile insert 70 can be a track defining one or more longitudinalchannels C that adjustably receives one or more logistic bars forrestraining cargo and/or auxiliary deck beams used for creating a loaddeck spaced above the trailer floor 14. The profile insert 70 andchannel(s) C therein typically are arranged with an elongatedlongitudinal direction extending in the direction of the trailer heightH, but may also extend in other directions such as the direction of thetrailer length L.

In the illustrated joint construction, each of the two adjoining panels515, 516 has both their skins 32, 34 formed to one common (exterior)side of the panel thickness to form a flange or edge portion 515A, 516A.This may be accomplished by forming the opposite (interior) skins 32 toa shape to allow both skins 32, 34 to be brought to a common surface forbonding. The two adjoining edge portions 515A, 516A can be entirelyoverlapped with each other as shown, and each edge portion 515A, 516Acan extend from the main portion of the respective panel 515, 516 todefine a width (in the left-right direction as shown in FIG. 8) that isapproximately equal to a width of the profile insert 70, for examplewithin 10 percent of the profile insert width W_(P). Thus, all fourskins 32, 34 (or any fraction thereof) can extend across the entirejoint, underneath the profile insert 70. In other constructions, the twoedge portions 515A, 516A may be only partially overlapped, or notoverlapped. The edge portions 515A, 516A and the joint formed therewithdefine a pocket or recess for receiving the profile insert 70, which isintegrally joined as part of the joint between the panels 515, 516. Theprofile insert 70 may be received by the pocket so as to be flush withthe interior surfaces of the interior skins 32 as shown, or may protrudeslightly from the pocket or be recessed slightly in the pocket in thepanel thickness direction.

Each panel core 30 may terminate at the respective side of the profileinsert 70 as shown so as to not extend into the edge portions 515A,516A, or may be provided with a reduced thickness (e.g., a flat sectionof the core along the common plane) thereby creating a 3-layer materialthickness for the edge portion 515A, 516A of each panel (or anycombination of the above described). In FIG. 8, the joint can be madewide enough to allow for multiple rows of fasteners to provide for theconnection. The fastening of the joint can be via one or more rows ofmechanical fasteners (e.g., screws, rivets, etc.), welding, adhesivebonding, or a combination of methods.

A panel edge treatment and a corresponding joint construction accordingto a seventh embodiment are shown in FIG. 9. This construction issimilar to the joint shown in FIG. 8, except as described below.Although the skins 32, 34 are formed as described above to create flangeor edge portions 615A, 616A defining a pocket for a profile insert 72,the edge portions 615A, 616A of FIG. 9 are narrower in a directionextending away from the main panel portions toward the adjoining panel.The narrower construction accommodates or conforms to a narrower profileinsert 72, in this case having a single channel C. The integral profileinsert 72 of FIG. 9 can have a width W_(P) that is less than twice thepanel thickness (T1+2T), whereas the width W_(P) of the profile insert70 of FIG. 8 can be more than two times or even more than three timesthe panel thickness. The joint, including the profile insert 72 of FIG.9, may be fastened with a single row of mechanical fasteners, althoughany of the fastening options described above may also be used in lieu ofor in combination with a single row of mechanical fasteners.

FIG. 10 illustrates a portion of a single composite panel 715, ratherthan a joint between panels. It will be understood that the panel 715may have any one of the illustrated edge treatments described above, oralternatives thereof, and the above description is referred to fornumerous details of the panel 715 and its components in order to avoidredundancy. The panel 715 provides a pocket or recess 80 for insertionof one or more profile inserts (not shown) at any predetermined locationin the panel 715. The recess 80 can be located centrally within thepanel 715, or any other position across the panel 715, and can beelongated to extend along the panel 715 in a direction of the trailerheight H (e.g., along the entire panel height, or a portion thereof). Insome constructions, one or more recesses may extend across the width ofthe panel 715 (e.g., in a direction of the trailer length L). It is alsocontemplated to place multiple recesses across the width of the panel(i.e. running edge to edge) based upon radial placement of flatteningbars. The core 30 may be provided in separate sections on opposing sidesof the recess 80 or a reduced (e.g., flat) core section may be provideddirectly under the recess 80, continuous or discontinuous with one orboth of the core sections flanking the recess 80. The recess(es) 80 canbe utilized to accommodate structures (e.g., brackets, electricalwiring, piping, etc.) which may otherwise require an irregular inner orouter shaping of the trailer 10. As such, the inclusion of the recess 80enables a wind drag reduction for better fuel efficiency whentransporting the trailer 10 and/or a smoother interior wall surface toreduce cargo hang-up or snagging during loading and unloading.

An additional trailer joint having similarities to the above describedjoint constructions is shown in FIGS. 11-12. Rather than a sidewalljoint, the joint is formed between a roof panel 813 and the trailerupper rail 22. Although not shown, the roof 13 may consist of aplurality of the roof panels 813 joined together by any one of the jointtypes set forth herein, among others. The roof panel 813 can have a core30 similar to any of the above-described constructions, and can besandwiched between an inner skin 832 and an outer skin 834. In someconstructions, the core 30, and the panel 813 as a whole spans the fullwidth W of the trailer 10 such that the panel 813 is formed with twoopposing edge portions 813A (one shown) configured to engage theopposing lengthwise upper rails 22 of the trailer 10. In otherconstructions, at least one joint is made with another panel across thewidth direction of the roof 13.

The edge portion 813 can be a flat flange formed by one or both of theskins 832, 834. As illustrated, the interior skin 832 wraps 90-degreesaround an edge of the core 30 toward the exterior skin 834 (i.e., skinportion 832A) before wrapping 90-degrees again to run directly under theexterior skin 834, alongside a top surface 22A of the upper rail 22(i.e., skin portion 832B). Although shown with bends forming 90-degreeangles, it is also contemplated that the interior skin 832 can be bentto form angles greater than 90 degrees. The exterior skin 834 can extendalong a consistent planar direction in the main panel portion having thecore 30 and also the edge portion 813A extending along the upper rail 22(i.e., skin portion 834A). The skins 832, 834 defining the edge portion813A can be secured to the upper rail 22 with one or more rows ofmechanical fasteners 38 (e.g., screws, rivets, etc.), welding, adhesivebonding, or a combination of methods. As illustrated, the edge portion813A can further be formed with a lip that wraps around alaterally-distal edge 22B of the upper rail 22. The lip can include(e.g., 180-degree) rolled edge portions 832C, 834B of both the interiorand exterior skins 832, 834. Alternatively, the edge may be left flat(i.e., the rolled edge portions 832C, 834B eliminated) and a profilededge cap added as the fastening and sealing component. The edge cap (notshown) can have a shape similar to the portions 834A, 834B.

As illustrated in FIG. 13, a multi-layer floor platen 914 may beconstructed utilizing similar materials and construction techniques asthose described above. The floor platen 914 can include an interior skin932 and an exterior skin 934, between which a core 930 is sandwiched.The core 930 can include multiple profiled core sheets 30, each having ashape and material construction as described above. In fact, the coresheets 30 of the floor platen 914 can have an identical cross-sectionalprofile to cores 30 used in the sidewalls 12 and/or roof 13 of thetrailer 10. In some constructions, each core sheet 30 has a thickness T1of 0.75 inch, and the total thickness of the core 930 is 2.25 inches.Each core sheet 30 can include an array of interspersed peaks andvalleys, with the adjacent core sheets 30 stacked to establish onlyfacing peak-to-peak contact rather than nested peak-into-valley contact.As such, void space and overall thickness are maximized for themulti-layer core 930. As an alternative, a single profiled core sheetmay be used to construct the floor platen 914. Such a core sheet may beprofiled with peaks and valleys to define an overall core thickness ofover 1.0 inch (e.g., 1.5 inches or more) in some constructions. Althoughnot shown, additional interstitial skins can also be provided betweenadjacent overlying core sheets 30 within the floor platen 914. Thestructure may be provided as the substructure of the trailer floor 14.For additional strength, more or taller core sheets 30 may be added. Useof the floor plate 914 may allow for elimination of cross-member typeconstruction, resulting in a reduction in aerodynamic drag.

FIGS. 14 and 15 illustrate an example of a core sheet 30 used inconstructing the floor platen 914 or any of the above-described panels.As previously mentioned, the core sheet 30 can be draw formed from aflat metal sheet to form an array of spaced apart peaks P and valleys V,at regular or irregular intervals. The sheet can be embossed (i.e.,pressed by an embossing roll or drum to create reliefs in one direction)or dual embossed (i.e., drawn in two opposing directions).Dual-embossing may include forming with two embossing drums withinterleaving projections or studs so that reliefs are drawn into thematerial in two opposite directions from the beginning plane of thematerial. It may be desirable to minimize the amount of material and tomaximize the amount of vacant space (within strength constraints of thematerial) in order to reduce the overall weight of the core sheet andthe panel. Each peak P can be formed by a raised area or “button”defining a contact point for contacting an adjacent skin sheet. Thepeaks P of one surface of the core sheet 30 define the locations of thevalleys V of the opposite surface of an adjacent core sheet 30, and viceversa. Although dimensions may vary based on selected material, loadratings, etc., the core sheet 30 in one construction defines apeak-to-peak spacing S of 0.750 inch in both coordinate directions and athickness T1 of 0.500 inch. The starting sheet may be not less than0.008 inch and not more than 0.016 inch thick in some constructions, andmore particularly, may be about 0.011 inch (0.010 inch to 0.012 inch),and the material may be galvanized steel, or aluminum, although theseparameters may vary by application. The peaks P and the valleys V may beprovided in varying densities (i.e., number per area) across a givencore sheet 30. In some constructions, the density of peaks P and valleysV is increased at edge portions of the core sheets 30, particularly inedge portions having a reduced thickness, examples of which aredescribed above.

FIGS. 16-20 illustrate panels and a corresponding joint constructionaccording to another embodiment. The embodiment of FIGS. 16-20incorporates features similar to some of the above-describedembodiments, including those of FIGS. 8-10. In addition, basic elements,such as the interior and exterior skins 1032, 1034, and the cores 30 canconform to the above description, which is referred to for numerousdetails of the panels 1015, 1016 and their components in order to avoidredundancy. It is also noted that FIG. 20 illustrates a completesidewall 1012 for a trailer, which may be similar to the trailer 10 ofFIGS. 1 and 2 as described above. As shown, the sidewall 1012 includes aseries of panels 1013-1019, each sequentially joined to one another. Thesidewall 1012 may have a “wedge” construction, in which the panels1013-1019 increase in height toward a rear end of the sidewall 1012(i.e., allowing a door opening generally equal to the trailer's interiorheight at the forward end, despite intrusive structure related to aroll-up door provided at the rear of the trailer). In constructing atrailer with the wedge sidewall 1012, the top edge of the trailer can begenerally parallel to ground, while the floor slopes down toward theground in the rearward direction. In some embodiments by way of example,the height H may increase about 4 inches from the leading or forward endto the rearward end.

As mentioned above, the panels 1013-1019 of FIGS. 16-20 incorporatefeatures similar to FIGS. 8-10. In particular, each of the panels1013-1019 includes a mid-panel recess 1080 to accommodate a profileinsert 1072 as in FIG. 10, and further includes edge treatmentsconfigured to be joined with adjacent panel(s) in a manner that alsointegrates additional profile inserts 1072 as in FIGS. 8 and 9. Themid-panel recess 1080 can be centrally located along each panel width(i.e., in the direction of sidewall/trailer length L) or locatedoff-center, but spaced from the parallel extending edges. Contrary tothe embodiments of FIGS. 8 and 9, the adjoining panels (1015, 1016 shownas exemplary in FIG. 16) form a recess that is not box-like orrectangular having walls angled at 90 degrees, but rather, form a recessthat is generally tapered or trapezoidal, being wider at the side of theinterior skin 1032. The profile insert 1072 can have a complementarytrapezoidal cross-section as shown in FIG. 16. The recess 1080 isdefined by a bottom wall generally in-plane with the exterior skins 1034and two opposing side walls 1080A, 1080B. Each side wall 1080A, 1080B isoriented such that an imaginary line extended to the interior side formsan acute angle α with the interior skin 1032 in the main portion of thepanel having the full core thickness T1. As illustrated, the angle α canbe 45 degrees, such that the total inclusive angle β of the recess 1080formed by the two side walls 1080A, 1080B is 90 degrees as shown in FIG.18. However, the angle α may be between 30 degrees and 60 degrees inother constructions, or any other acute angle in other constructions.The bottom wall of the recess 1080 can be formed by directly overlyingportions of the interior and exterior skins 1032, 1034 having no coretherebetween, although other constructions may utilize a reduced corethickness in this area. As shown in FIG. 18, the thickness of the core30 reduces (e.g., linearly) in a direction toward the recess 1080 in amanner similar to the shape of the core 30 at each distal panel edge asdescribed below. The width W_(P) at the bottom wall of the recess 1080can be 1 inch in some constructions, and the width W_(P1) of the recess1080 at the wider end, in-plane with the interior skin 1032, can be 2inches.

As shown in FIG. 16, two panels 1015, 1016 are joined to form a recessconfigured to accommodate a profile insert 1072 like that incorporatedmid-panel. However, rather than being formed solely by shaping of oneinterior skin 1032, the recess at each joint is formed by overlappingedge portions 1015B, 1016B of both adjoining panels 1015, 1016 and theadjacent co-facing edge portions (which mimic the shape of the sidewalls 1080A, 1080B of the mid-panel recess 1080). Each panel 1015, 1016includes a core 30 having a maximum core thickness T1. The core 30 has agradually reducing thickness T2 in a first edge portion 1015A, 1016Awhich then transitions to a second edge portion 1015B, 1016B having nocore, and consisting only of the overlying interior and exterior skins1032, 1034. Each of the second edge portions 1015B, 1016B defines aflange having a thickness T₃. The thickness T₃ can be less than 20percent of the total panel thickness TT (FIG. 19). Each second edgeportion 1015B, 1016B forming the flange extends from the cored portionof the panel by a width W_(B) (FIG. 19), which can be 1 inch in someconstructions. The panels 1015, 1016 can be joined together integrallywith the profile insert 1072 with a single row of mechanical fasteners,although any of the fastening options mentioned above may also be usedin lieu of or in combination with a single row of mechanical fasteners.The total panel thickness TT (equal to T₁+2T) can be between 0.500 inchand 0.600 inch in some constructions (e.g., 0.566 inch). It should benoted that this edge and joint construction may also be employed inpanels having no mid-panel recesses or mid-panel profile inserts.

All or a majority of the panels 1013-1019 can have a panel width W₁ ofabout 4 feet (i.e., 48 inches+/−2 inches), and profile inserts 1072 mayhave an on-center spacing S_(C) of about 2 feet (i.e., 24 inches+/−1inch) since there are profile inserts 1072 at both the joint locationsand the mid-panel locations. In other constructions, all or the majorityof the panels 1013-1019 can have a panel width W₁ of about 2 feet withno mid-panel profile inserts 1072 such that the on-center spacing S_(C)is also about 2 feet. In other constructions, the on-center spacingS_(C) is about 16 inches (i.e., 16 inches+/−1 inch). Finally, it shouldbe noted that specific features, shapes, or configurations of any or allof the above-described embodiments may be mixed and matched together,unless expressly prohibited, to result in additional embodiments notexplicitly illustrated or described herein. As one example, any of theearlier-described embodiments having parallel co-facing portions (e.g.,formed by a 90-degree bend in a panel skin), at the edges of twoadjoining panels and/or on opposing sides of a mid-panel recess, caninstead be formed to include non-parallel co-facing portions (e.g.,formed by a bend in a panel skin of less than 90 degrees, for example,30-60 degrees, or particularly 45 degrees).

What is claimed is:
 1. A cargo body comprising: a floor; a roof; and aplurality of sidewalls extending between the floor and the roof todefine a cargo receiving volume in cooperation with the floor and theroof, each one of the plurality of sidewalls constructed of a pluralityof panels including adjacent pairs of panels secured together atrespective joints, wherein each of the plurality of panels is acomposite panel having a core, an interior skin secured to a first sideof the core facing the cargo receiving volume, and an exterior skinsecured to a second side of the core opposite the first side, whereineach of the joints includes an interior splice plate and an exteriorsplice plate, and co-facing edge portions of the adjacent pair of panelsare sandwiched between the interior and exterior splice places, whereineach edge portion defines a region of reduced core thickness in which acore thickness measured between the respective interior and exteriorskins is less than a maximum core thickness measured between therespective interior and exterior skins, and wherein a recess is formedby the pair of interior skins or by the pair of exterior skins toreceive the corresponding one of the interior and exterior spliceplates, such that the corresponding one of the interior and exteriorsplice plate is nested into the recess.
 2. The cargo body of claim 1,wherein respective facing distal edges of the cores of the adjacentpairs of panels abut each other.
 3. The cargo body of claim 1, whereinrespective facing distal edges of the cores of the adjacent pairs ofpanels are spaced apart from each other.
 4. The cargo body of claim 3,further comprising at least one aperture formed in one of the interioror exterior splice plates, the at least one aperture being exposed to aspace defined between the respective facing distal edges.
 5. The cargobody of claim 3, wherein at least one of the facing distal edges of thecores is covered by a 90-degree bent portion of the interior or exteriorskin of the respective panel.
 6. The cargo body of claim 5, wherein eachof the facing distal edges of the cores is covered by a respective90-degree bent portion of the interior or exterior skin of therespective panel.
 7. The cargo body of claim 1, wherein each of theinterior and exterior splice plates has a thickness greater than theinterior and exterior skins.
 8. The cargo body of claim 1, wherein therecess is a first recess formed by the corresponding pair of interiorskins, and the interior splice plate is nested into the first recess,and further comprising a second recess formed by the corresponding pairof exterior skins, wherein the exterior splice plate is nested into thesecond recess.
 9. The cargo body of claim 8, wherein an exterior surfaceof the exterior splice plate is flush with exterior surfaces of theexterior skins of the adjacent pair of panels, and an interior surfaceof the interior splice plate is flush with interior surfaces of theinterior skins of the adjacent pair of panels.
 10. The cargo body ofclaim 1, wherein the at least one nested interior or exterior spliceplate is nested into the recess so as to not extend in a panel thicknessdirection beyond exposed faces of the interior or exterior skins thatreceive the nested splice plate.